Permanent, self-adhering, self-lubricating, anti-wear composite system

ABSTRACT

An anti-wear composite structure includes an anti-wear layer that has a wear surface opposite an adhesive receiving surface and a thermosetting resin applied to the adhesive receiving surface. The thermosetting resin includes a reactive adhesive configured to bond the anti-wear composite structure to a substrate at an ambient temperature band via pressure-sensitive adhesion. The thermosetting resin has an onset to cure in the ambient temperature band and has a peak cure temperature greater than the ambient temperature band to mechanically and chemically bond the anti-wear composite structure to a substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/889,183 filed on Aug. 20, 2019, which isincorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention is directed to an anti-wear composite structureand more specifically to an anti-wear composite structure having ananti-wear layer and a thermosetting resin, applied to one side of theanti-wear layer, configured to bond (e.g., temporarily bond or aprecursor bond) to a substrate at an ambient temperature band viapressure-sensitive adhesion, having an onset to cure at ambienttemperature and having a peak cure temperature greater than the ambienttemperature band to mechanically and chemically bond (e.g., permanentlybond) the anti-wear composite structure to a substrate.

BACKGROUND

Anti-wear materials can be installed in many areas of aerospace orindustrial mating surfaces to prevent the galling or fretting resultingfrom metal on metal sliding wear. The anti-wear materials aretraditionally adhered to a substrate using a two-part epoxy which isapplied by hand. This method of adhesion is difficult, perhapsimpossible, to apply evenly with typical aerospace bond lines of 0.002″to 0.004″ thick. The prior art adhesives are difficult to clean,wasteful (e.g., flash and container loss) and have ambient curing timesof 24 to 72 hours. Flash is adhesive that bleeds from the bond lineduring curing and container loss is the adhesive lost to the sides ofthe container during mixing/dispensing.

Based on the foregoing, there is a need to provide an improved anti-wearmaterial that is easy to install and can overcome the foregoinglimitations.

SUMMARY

The present invention includes an anti-wear composite structure thatincludes an anti-wear layer that has a wear surface opposite an adhesivereceiving surface and a thermosetting resin applied to the adhesivereceiving surface. The thermosetting resin includes a reactive adhesiveconfigured to bond (e.g., temporarily bond or a precursor bond) theanti-wear composite structure to a substrate at an ambient temperatureband (e.g., 22.22 degrees Celsius plus or minus 8.33 degrees Celsius; or72 degrees Fahrenheit plus or minus 15 degrees Fahrenheit) viapressure-sensitive adhesion. The thermosetting resin has an onset tocure in the ambient temperature band and has a peak cure temperaturegreater than the ambient temperature band to mechanically and chemicallybond (e.g., permanently bond) the anti-wear composite structure to asubstrate.

In some embodiments, the anti-wear layer is a woven structure, such as,for example, a thermally-consolidated, fabric reinforced-polymer matrixwith self-lubricating components integral to a weave and/or as anadditive to the matrix.

In some embodiments, the woven structure is woven fabric that has aplurality of fibers interwoven with one another andpolytetrafluoroethylene (PTFE) interwoven therewith. In someembodiments, the fibers include a polyester material, a stainless steelmaterial, PTFE and/or glass material.

In some embodiments, the anti-wear layer is a thermally-consolidated,machinable, moldable or non-woven fabric, comprising a reinforcedpolymer matrix composite with self-lubricating materials integral to thenon-woven fabric and/or as an additive to the matrix.

In some embodiments, the thermosetting resin is in the form of a tapecalendered, or laminated, to one side of the anti-wear layer.

In some embodiments, the thermosetting resin is configured to be appliedto the anti-wear layer in viscous form via resin application techniquescomprising at least one of painting, brushing, rolling, and squeezing.

The thermosetting resin is configured to be dried to increase roomtemperature viscosity to allow for pressure sensitive adhesion withoutflash or squeeze-out during application to a substrate.

In some embodiments, a protective layer is removably adhered to theanti-wear layer and configured to be removed before or after bonding andbefore use in a service application.

In some embodiments, the protective layer includes indicia configured asadvertising and/or instructions for installation and use.

In some embodiments, a release layer is removably adhered to thethermosetting resin and the release layer is configured to be entirelyremoved from the thermosetting resin prior to bonding to a substrate.The release layer can be made from a siliconized paper or polymer film.

The present invention includes a method of applying an anti-wearcomposite structure to a substrate. The method includes, providing ananti-wear composite structure having an anti-wear layer that has a layerof thermosetting resin applied to an adhesive receiving surface of theanti-wear layer; a protective layer that is removably adhered to a wearsurface of the anti-wear layer; and a release layer that is removablyadhered to a surface of the thermosetting resin. The method includesmaintaining the anti-wear composite structure at a temperature more than22.22 degrees Celsius (40 degrees Fahrenheit) below ambient temperature(e.g., below zero degrees Celsius; or below 32 degrees Fahrenheit)before installation to prevent premature curing of the thermo settingresin. The method includes removing a release layer from thethermosetting resin and the adhering the thermosetting resin portion ofthe anti-wear structure to the substrate via pressure-sensitive adhesionat ambient temperature. The method includes applying pressure to theanti-wear composite structure via the protective layer disposed on theanti-wear layer; and heating the anti-wear composite structure to atemperature sufficient to cure the thermosetting resin and mechanicallyand chemically bond the thermosetting resin to the substrate.

In some embodiments, the protective layer is removed from the anti-wearlayer.

The present invention includes a method of manufacturing the anti-wearcomposite structure via forming the anti-wear composite structure intospecific shapes via cutting, shaping, die stamping, computer numericalcontrolled machining (CNC) and/or hand trimming.

The present invention includes an anti-wear composite structure thatincludes an anti-wear layer that has a wear surface opposite an adhesivereceiving surface. The anti-wear composite structure includes athermosetting resin applied to the adhesive receiving surface. Theanti-wear composite structure includes a protective layer that isremovably adhered to the anti-wear layer and configured to be removedbefore or after bonding and before use in a service application. Theanti-wear composite structure includes a release layer removably adheredto the thermosetting resin. The release layer is configured to beentirely removed from the thermosetting resin prior to bonding to thesubstrate. The thermosetting resin includes a reactive adhesiveconfigured to bond the anti-wear composite structure to a substrate atan ambient temperature band via pressure-sensitive adhesion, that has anonset to cure in the ambient temperature band and has a peak curetemperature greater than the ambient temperature band to mechanicallyand chemically bond the anti-wear composite structure to the substrate.

In some embodiments, the thermosetting resin is configured to be driedto increase room temperature viscosity to allow for pressure sensitiveadhesion without resin flowing from the bond line during application tothe substrate.

The present invention includes an anti-wear composite structure thatincludes an anti-wear layer that has a wear surface opposite an adhesivereceiving surface. The anti-wear composite structure includes athermoplastic adhesive applied to the adhesive receiving surface. Thethermoplastic adhesive is configured to removably bond the anti-wearcomposite structure to a substrate at a temperature of about 138 degreesCelsius (280 degrees Fahrenheit) to about 160 degrees Celsius (320degrees Fahrenheit).

In some embodiments, the anti-wear composite structure includes aprotective layer removably adhered to the anti-wear layer and configuredto be removed before or after bonding and before use in a serviceapplication; and/or a release layer removably adhered to thethermoplastic adhesive, the release layer being configured to beentirely removed from the thermoplastic adhesive prior to bonding to thesubstrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional view of the anti-wear composite structure ofthe present invention;

FIG. 2 is a cross sectional view of the anti-wear composite structure ofthe present invention shown with a release layer being peeled off;

FIG. 3 is a cross sectional view of the anti-wear composite structure ofthe present invention shown with the release layer peeled off and theanti-wear composite structure adhered to a substrate;

FIG. 4 is a cross sectional view of the anti-wear composite structure ofthe present invention shown with a protective layer being peeled off;

FIG. 5 is a cross sectional view of the anti-wear composite structure ofthe present invention shown with the proactive layer and release layerpeeled off and the anti-wear composite structure cured and adhered tothe substrate;

FIG. 6 is a schematic cross sectional view of a woven anti-wear layer;

FIG. 7 is an exploded perspective view of the anti-wear compositestructure of the present invention;

FIG. 8 is a cross sectional view of the anti-wear composite structure ofthe present invention with a thermoplastic tape; and

FIG. 9 is a is a cross sectional view of the anti-wear compositestructure FIG. 8 shown with the proactive layer and release layer peeledoff, the anti-wear composite structure cured and adhered to thesubstrate and a panel.

DETAILED DESCRIPTION

As shown in FIG. 1, an anti-wear composite structure of the presentinvention is generally designated by the numeral 10. The anti-wearcomposite structure 10 includes an anti-wear layer 30 (e.g., asolid-state, self-lubricating, anti-wear, composite layer, a sheet, afilm or a thickness) having a wear surface 32 opposite an adhesivereceiving surface 34. Thus, the wear surface 32 and the adhesivereceiving surface 34 are on opposing sides of the anti-wear layer 30.The anti-wear composite structure 10 includes a thin layer ofthermosetting resin 40 (i.e., adhesive) applied to the adhesivereceiving surface 34.

In some embodiments, the thermosetting resin 40 (i.e., adhesive) appliedonly to the adhesive receiving surface 34. In some embodiments, thethermosetting resin 40 is applied to the entire adhesive receivingsurface 34. In one embodiment, the thermosetting resin 40 is applied toportions of the adhesive receiving surface 34, for example in a pattern.The thermosetting resin 40 is applied uniformly (i.e., a predeterminedthickness) to the adhesive receiving surface 34 of the anti-wear layer30.

While the thermosetting resin 40 is shown and described as being applieduniformly (i.e., a predetermined thickness) to the adhesive receivingsurface 34 of the anti-wear layer 30, the present invention is notlimited in this regard as the thermosetting resin 40 may be applied innon-uniform and various thicknesses to the adhesive receiving surface 34of the anti-wear layer 30 to comport with non-uniform shape, contour orirregularities in the surface of a substrate 60 that the anti-wearcomposite structure 10 is applied to.

While FIG. 1 illustrates the anti-wear composite structure 10 as beinggenerally flat with the protective layer 20, anti-wear layer 30, thelayer of thermosetting resin 40 and the release layer 50 beingsubstantially flat and parallel to one another, the present invention isnot limited in this regard as the anti-wear composite structure 10 mayhave other shapes and configurations including but not limited toarcuate shapes and shapes with corners. In one embodiment, the anti-wearcomposite structure 10 is flexible, pliable and is conformable to ashape (e.g., arcuate shape) of the substrate 60.

The thermosetting resin 40 includes a reactive adhesive that has a firstbonding step and a second bonding step. During the first bonding stepthe reactive adhesive is configured to initially bond (e.g., temporarilybond or a precursor bond) the anti-wear composite structure 10 to asubstrate 60 (see FIG. 3) at an ambient temperature band (e.g., 22.22degrees Celsius plus or minus 8.33 degrees Celsius; or 72 degreesFahrenheit plus or minus 15 degrees Fahrenheit) via pressure-sensitiveadhesion. The first bonding steps allows the thermosetting resin 40 ofthe anti-wear composite structure 10 to be positioned on the substratein preparation for performing the second bonding step. After the firstbonding step is complete, the second bonding step is performed. Thethermosetting resin 40 has an onset to cure and high tack in the ambienttemperature band and has a peak cure temperature greater than theambient temperature band to perform the second bonding step whichmechanically and chemically bonds (e.g., permanently bonds) theanti-wear composite structure 10 to the substrate 60 (e.g., metal orcomposite substrate). The anti-wear composite structure 10 isclean-handling, easy to install, dimensionally uniform, can be fixed toany roughened substrate similar to a pressure sensitive adhesionmaterial, and cures when heated under pressure, for example underautoclave in 1 hour.

During the second bonding step, the reactive adhesive in thermosettingresin 40 of the anti-wear composite structure 10 is cured at a pressureof 2.06843 Bar to 6.89476 Bar (30 to 100 pounds per square inch), atemperature of 148.89 degrees Celsius to 204.444 degrees Celsius (300 to400 degrees Fahrenheit) with a range of time from 30 to 90 minutes. Inone embodiment, during the second bonding step the reactive adhesive inthermosetting resin 40 of the anti-wear composite structure 10 is curedat a pressure of 3.44738 Bar (50 pounds per square inch-) and atemperature of 176.667 degrees Celsius (350 degrees Fahrenheit) for 60minutes.

As shown in FIG. 6, in some embodiments the anti-wear layer 30 includesa woven structure 80. The woven structure 80 is made up of athermally-consolidated, fabric reinforced-polymer matrix withself-lubricating components integral to a weave and/or as an additive tothe matrix. The woven structure 80 includes a woven fabric that has aplurality of fibers 80A, 80B, 80C, and 80D interwoven with one anotherand polytetrafluoroethylene (PTFE) fibers 84 interwoven therewith. Thefibers 80A, 80B, 80C, and 80D include those made of a polyestermaterial, a stainless steel material, a PTFE material and a glassmaterial or combinations thereof.

In some embodiments, the anti-wear layer 30 is a thermally-consolidated,machinable, moldable or non-woven fabric that has a reinforced polymermatrix composite with self-lubricating materials integral to thenon-woven fabric and/or as an additive to the matrix.

In some embodiments, the thermosetting resin 40 is in the form of a tapecalendered, or laminated, to one side of the anti-wear layer 30. In someembodiments, the thermosetting resin 40 is configured to be applied tothe anti-wear layer in viscous form via resin application techniquescomprising at least one of painting, brushing, rolling, and squeezing.

In some embodiments, the thermosetting resin 40 is configured to bedried to increase room temperature viscosity to allow for pressuresensitive adhesion without resin flowing from the bond line duringapplication to a substrate 60.

As shown in FIG. 1, a protective layer 20 is semi-permanently adhered to(i.e., removably adhered to) the anti-wear layer 30 and is configured tobe removed before or after bonding and before use in a serviceapplication. The protective layer 20 is shown in the process of beingremoved (e.g., peeled off as indicated by the arrow P2) from theanti-wear layer 30 in FIG. 4. FIG. 5 illustrates the anti-wear compositestructure 10 cured bonded (e.g., permanently bonded) on the substratewith both the protective layer 20 and the release layer 50 removedtherefrom. In some embodiments, the protective layer 20 includes indiciasuch as advertising and/or instructions for installation and use printedor formed thereon. The protective layer 20 is manufactured from anon-porous material, such as a polyester film to uniformly distributepressure across the surface of the anti-wear composite structure 10during the heat and pressure application stage of the curing and bondingprocess. The protective layer 20 also prevents premature damage to theanti-wear layer 30 before installation, for example during shipping andhandling.

As shown in FIG. 1, the anti-wear composite structure 10 includes arelease layer 50 semi-permanently adhered to or removably adhered to asurface 42 of the thermosetting resin 40. The release layer isconfigured to be entirely removed from the thermosetting resin 40 priorto bonding to a substrate 60. The release layer 50 is shown in a processbeing removed (e.g., peeled off) in FIG. 2, as indicated by the arrowP1. In some embodiments, the release 50 layer is a siliconized paper orpolymer film 52.

The protective layer 20 has a thickness T1 in the range of 0.00508 cm to0.03048 cm (0.002 inches to 0.012 inches). The anti-wear layer 30 has athickness T2 in the range of 0.00508 cm to 0.3048 cm (0.002 inches to0.120 inches). The thermosetting resin 40 has a thickness T3 in therange of 0.00508 cm to 0.0254 cm (0.002 inches to 0.010 inches). Therelease layer 50 has a thickness T4 in the range of 0.00508 cm to0.03048 cm (0.002 inches to 0.012 inches).

As shown in FIG. 5, the wear surface 32 of the anti-wear layer 30 is insliding engagement with a mating surface 72 of component 70. Theanti-wear layer 30 provides resistance to galling and fretting of themating surface 72 while providing a low friction interface between theanti-wear layer 30 and the mating surface 72.

While FIGS. 1-5 show and describe the anti-wear composite structure 10with the thin layer of thermosetting resin 40 applied to the adhesivereceiving surface 34 of the anti-wear layer 30, the present invention isnot limited in this regard as the thin layer of thermosetting resin 40may be replaced with a thin layer of thermoplastic adhesive tape 140, asshown in FIG. 8 for the anti-wear composite structure 110. The thinlayer of thermoplastic adhesive tape 140 is applied to the adhesivereceiving surface 34 of the anti-wear layer 30 via a suitable processsuch as calendaring. In one embodiment, the thermoplastic adhesive tape140 is a thermoplastic polyurethane and is installed with heat to about138 degrees Celsius (280 degrees Fahrenheit) to about 160 degreesCelsius (320 degrees Fahrenheit) and preferable to approximately 149degrees Celsius (300 degrees Fahrenheit). The anti-wear compositestructure 110 has the release layer 50 applied to the surface 42 of thethermoplastic adhesive tape 140. In addition, the protective layer 20 isapplied to the wear surface 32 of the anti-wear layer 30.

The anti-wear composite structure 110 shown in FIG. 8 is suitable forsituations where an anti-wear layer 30 requires temporary fixation to apanel because the panel will ultimately be fixed by mechanical means toa substrate. For example, as shown in FIG. 9, the anti-wear compositestructure 110 has the protective layer 20 removed and the release layer50 removed. The anti-wear layer 30 is removably adhered to the substrate60 (e.g., a panel) with the thermoplastic adhesive tape 140 by heatingto approximately 149 degrees Celsius (300 Fahrenheit). The substrate 60is mechanically secured to the component 70 with mechanical fastenerssuch as bolts 77 and nuts 78. The anti-wear layer 30 prevents galling ofthe mating surface 72 of the component 70. When it comes time to replacethe anti-wear composite structure 110, the thermoplastic adhesive tape140 will peel away cleanly from the substrate 60, with minimal effort.

The substrate 60 has a service temperature of −54 degrees Celsius to 52degrees Celsius (65 degrees Fahrenheit to 125 degrees Fahrenheit) Theoverall advantage of the thermoplastic adhesive tape 140 is ease (andspeed) of installation and cleanup at the sacrifice of a permanentchemical bond (which imparts creep resistance, temperature resistance,modulus, strength and chemical resistance). If for some reason, thesubstrate 60 reached the melting temperature of the thermoplasticadhesive tape 140, the thermoplastic adhesive tape 140 would losestructure, but would this be inconsequential due to the mechanicalfixation of the substrate 60 to the component 70.

The present invention also includes a method of applying an anti-wearcomposite structure 10 to a substrate 60. The method includes providingthe anti-wear composite structure 10 illustrated in FIG. 1, includingproviding the anti-wear layer 30 having the thin layer of thermosettingresin 40 applied to the adhesive receiving surface 34; the protectivelayer 20 removably adhered to the wear surface 34 of the anti-wear layer30; and the release layer 50 removably adhered to the surface 42 of thethermosetting resin 40. The temperature of the anti-wear compositestructure 10 is maintained at a temperature more than 22.22 degreesCelsius (40 degrees Fahrenheit) below ambient temperature of 22.22degrees Celsius (72 degrees Fahrenheit) before installation on thesubstrate 60 to prevent premature curing of the thermo setting resin 40.For example, the anti-wear composite structure 10 is maintained at atemperature below zero degrees Celsius (below 32 degrees Fahrenheit).The method includes removing the release layer 50 from the thermosettingresin 40. The thermosetting resin 50 portion of the anti-wear structure10 is adhered (e.g., temporarily bonded or precursor bonded) to thesubstrate 60 via pressure-sensitive adhesion at ambient temperature(e.g. 22.22 degrees Celsius plus or minus 8.33 degrees Celsius; or 72degrees Fahrenheit plus or minus 15 degrees Fahrenheit). The methodincludes applying pressure to the anti-wear composite structure 10 viathe protective layer 20. The method further includes heating theanti-wear composite structure 10 to a temperature sufficient to cure thethermosetting resin and mechanically and chemically permanently bond tothe substrate 60. The curing of the thermosetting resin 40 can furtherinclude applying pressure to the anti-wear composite structure 10, forexample, via application of pressure to the protective layer 20.

The method further includes removing the protective layer 20 from theanti-wear layer 30.

There is disclosed herein a method of manufacturing the anti-wearcomposite structure 10 that includes forming the anti-wear compositestructure 10 to specific shapes via at least one of cutting, shaping,die stamping, computer numerical controlled machining (CNC) and handtrimming.

Although this invention has been shown and described with respect to thedetailed embodiments thereof, it will be understood by those of skill inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of theinvention. In addition, modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodimentsdisclosed in the above detailed description, but that the invention willinclude all embodiments falling within the scope of the appended claims.

What is claimed is:
 1. An anti-wear composite structure comprising: an anti-wear layer having a wear surface opposite an adhesive receiving surface; and a thermosetting resin applied to the adhesive receiving surface; wherein the thermosetting resin comprises a reactive adhesive configured to bond the anti-wear composite structure to a substrate at an ambient temperature band via pressure-sensitive adhesion, having an onset to cure in the ambient temperature band and having a peak cure temperature greater than the ambient temperature band to mechanically and chemically bond the anti-wear composite structure to the substrate.
 2. The anti-wear composite structure of claim 1, wherein the anti-wear layer comprises a woven structure.
 3. The anti-wear composite structure of claim 2, wherein the woven structure comprises a thermally-consolidated, fabric reinforced-polymer matrix with self-lubricating components being at least one of integral to a weave and as an additive to the matrix.
 4. The anti-wear composite structure of claim 2, wherein the woven structure comprises woven fabric comprising a plurality of fibers interwoven with one another and polytetrafluoroethylene interwoven therewith.
 5. The anti-wear composite structure of claim 4, wherein the fibers comprise at least one of a polyester material, a stainless steel material, polytetrafluoroethylene and glass material.
 6. The anti-wear composite structure of claim 1, wherein the anti-wear layer is a thermally-consolidated, machinable, moldable or non-woven fabric, comprising a reinforced polymer matrix composite with self-lubricating materials integral to the non-woven fabric and/or as an additive to the matrix.
 7. The anti-wear composite structure of claim 1, wherein the thermosetting resin is in the form of a tape calendered, or laminated, to one side of the anti-wear layer.
 8. The anti-wear composite structure of claim 1, wherein the thermosetting resin is configured to be applied to the anti-wear layer in viscous form via resin application techniques comprising at least one of painting, brushing, rolling, and squeezing.
 9. The anti-wear composite structure of claim 1, wherein the thermosetting resin is configured to be dried to increase room temperature viscosity to allow for pressure sensitive adhesion without resin flowing from the bond line during application to the substrate.
 10. The anti-wear composite structure of claim 1, further comprising a protective layer removably adhered to the anti-wear layer and configured to be removed before or after bonding and before use in a service application.
 11. The anti-wear composite structure of claim 8, wherein the protective layer comprises indicia configured as advertising and/or instructions for installation and use.
 12. The anti-wear composite structure of claim 1, further comprising a release layer removably adhered to the thermosetting resin, the release layer being configured to be entirely removed from the thermosetting resin prior to bonding to the substrate.
 13. The anti-wear composite structure of claim 1, wherein the release layer comprises a siliconized paper or polymer film.
 14. A method of applying an anti-wear composite structure to a substrate, the method comprising; providing an anti-wear composite structure comprising an anti-wear layer having a layer of thermosetting resin applied to an adhesive receiving surface of the anti-wear layer; a protective layer removably adhered to a wear surface of the anti-wear layer; and a release layer removably adhered to a surface of the thermosetting resin; maintaining the anti-wear composite structure at a temperature more than 22.22 degrees Celsius below ambient temperature before installation to prevent premature curing of the thermo setting resin; removing a release layer from the thermosetting resin; adhering the thermosetting resin portion of the anti-wear structure to the substrate via pressure-sensitive adhesion at ambient temperature; applying pressure to the anti-wear composite structure via a protective layer disposed on the anti-wear layer; and heating the anti-wear composite structure to a temperature sufficient to cure the thermosetting resin and mechanically and chemically bond the thermosetting resin to the substrate.
 15. The method of claim 14, further comprising removing the protective layer from the anti-wear layer.
 16. A method of manufacturing the anti-wear composite structure of claim 1 comprising forming the anti-wear composite structure to specific shapes via at least one of cutting, shaping, die stamping, computer numerical controlled machining and hand trimming.
 17. An anti-wear composite structure comprising: an anti-wear layer having a wear surface opposite an adhesive receiving surface; and a thermosetting resin applied to the adhesive receiving surface; a protective layer removably adhered to the anti-wear layer and configured to be removed before or after bonding and before use in a service application; a release layer removably adhered to the thermosetting resin, the release layer being configured to be entirely removed from the thermosetting resin prior to bonding to the substrate; wherein the thermosetting resin comprises a reactive adhesive configured to bond the anti-wear composite structure to a substrate at an ambient temperature band via pressure-sensitive adhesion, having an onset to cure in the ambient temperature band and having a peak cure temperature greater than the ambient temperature band to mechanically and chemically bond the anti-wear composite structure to the substrate.
 18. The anti-wear composite structure of claim 17, wherein the thermosetting resin is configured to be dried to increase room temperature viscosity to allow for pressure sensitive adhesion without resin flowing from the bond line during application to the substrate.
 19. An anti-wear composite structure comprising: an anti-wear layer having a wear surface opposite an adhesive receiving surface; and a thermoplastic adhesive applied to the adhesive receiving surface; wherein the thermoplastic adhesive is configured to removably bond the anti-wear composite structure to a substrate at a temperature of about 138 degrees Celsius (280 degrees Fahrenheit) to about 160 degrees Celsius (320 degrees Fahrenheit).
 20. The anti-wear composite structure of claim 19, further comprising at least one of: a protective layer removably adhered to the anti-wear layer and configured to be removed before or after bonding and before use in a service application; and a release layer removably adhered to the thermoplastic adhesive, the release layer being configured to be entirely removed from the thermoplastic adhesive prior to bonding to the substrate. 